Plurality of studs being friction welded to an exterior surface of a curved structure having a block patch and a steel patch between the exterior surface and the studs

ABSTRACT

In some implementations, an apparatus comprises a pipe, a stud that is forge-welded to the pipe, creating a forge-welded stud, a bracket that is operably coupled to the forge-welded stud, and a ladder support operably coupled to the bracket.

RELATED APPLICATIONS

This application is a continuation of, and claims the benefit andpriority under 35 U.S.C. 120 of U.S. application Ser. No. 17/694,526filed on 14 Mar. 2022 having now patent Ser. No. 11/592,117 issued on 28Feb. 2023, which is a continuation of, and claims the benefit andpriority under 35 U.S.C. 120 of U.S. application Ser. No. 16/999,056filed on 20 Aug. 2020 having now patent Ser. No. 11/274,763 issued on 15Mar. 2022, which is a continuation of, and claims the benefit andpriority under 35 U.S.C. 120 of co-pending U.S. application Ser. No.16/174,162 filed on 29 Oct. 2017 having, which is a continuation of andclaims the benefit and priority under 35 U.S.C. 120 of U.S. applicationSer. No. 15/832,759 filed on 5 Dec. 2017 having now patent Ser. No.10/113,659 issued on 30 Oct. 2018 which is a continuation of, and claimsthe benefit and priority under 35 U.S.C. 120 of U.S. application Ser.No. 15/187,776 filed on 20 Jun. 2016 having now U.S. Pat. No. 9,835,262issued on 5 Dec. 2017 which is a continuation of, and claims the benefitand priority under 35 U.S.C. 120 of U.S. application Ser. No. 13/918,956having filed on 15 Jul. 2013 now U.S. Pat. No. 9,371,951 issued on 21Jun. 2016, which is hereby incorporated by reference in its entirety,which claims the benefit of U.S. Provisional Application Ser. No.61/760,646 filed 4 Feb. 2013 under 35 U.S.C. 119(e), which also claimsthe benefit of U.S. Provisional Application Ser. No. 61/835,563 filed 15Jun. 2013 under 35 U.S.C. 119(e).

FIELD

The present disclosure generally relates to repair of valves, pipes andpipe components and more specifically relates to techniques andapparatus of repair of valves, pipes and pipe components.

BACKGROUND

Millions of miles of piping and millions of control valves are installedthroughout the world. These valves control the flow of fluids and gasthrough pipes that route chemicals through refineries, storagefacilities, underground, marine vessels and space. Pipes need repair andsometimes feature enhancements such as electric terminals for cathodicprotection or mechanical fasteners for stairs, ladders and walkways.Valves are mechanical devices with moving parts. The moving parts wearout or corrode over time, causing leaks. With aging equipment fightingincreased clean air, water and soil standards, the need for valve, pipeand pipe component repair is growing rapidly.

Many pipes, valves and pipe components contain chemicals that arevolatile or caustic with unsafe leakage levels measured in parts permillion (ppm). Not only are these chemicals hazardous to theenvironment, but also to the technicians who are repairing them.

When a valve begins to leak in a refinery, the refinery must be takenout of service, costing millions of dollars a day or the valve leakneeds to be repaired while it is in-service. To do this, petrochemicalservice technicians, drill a hole partially through the valve housingnear the gland packing, thread this hole and then screw on a fittingthat will eventually allow drilling and injecting new sealant. Thisthreading process is fraught with problems. First, if the techniciandrills too deep into the bell housing, he could be exposed to hazardouschemicals threatening his life. In addition, once the fitting isattached to the thin wall of the housing, it is secured by only a fewthreads. This makes the fitting subject to breakage in the harshphysical environment of a refinery. In addition, threads can become apoint of leakage as corrosion and mechanical vibration weaken theconnection. During the process of injecting new sealant into the valve,existing injection processes allow hazardous material to escape into theenvironment, exposing the repair technician to hazardous chemicals andviolating ever tightening EPA rules.

In the past, if a fastener such as a stud, boss, nut, pin, screw, hinge,fitting, lever or clamp were attached to a pipe or valve, arc, MIG, TIGwelding, GMAW, GTAW, FCAW or SMAW or oxy-acetylene torch brazing wasutilized. Because of the high temperatures and sparks associate withthese welding processes, they cannot be used in hazardous environments.

BRIEF DESCRIPTION OF THE DRAWINGS

It will be appreciated that for simplicity and clarity of illustration,elements illustrated in the figures have not necessarily been drawn toscale. For example, the dimensions of some of the elements areexaggerated relative to other elements. Embodiments incorporatingteachings of the present disclosure are shown and described with respectto the drawings presented herein, in which:

FIG. 1 is an isometric diagram of a conventional gate valve, accordingto an implementation;

FIG. 2 is a cross section diagram of the gate valve in FIG. 1 ,according to an implementation;

FIG. 3 is a complete repair system with the injection system alignedwith a valve, according to an implementation;

FIG. 4 is an exploded isometric view of an injection system, accordingto an implementation;

FIG. 5 is a cross sectional isometric view of the injection system shownin FIG. 4 , according to an implementation;

FIG. 6 is an assembled isometric view of the injection system show inFIG. 4 , according to an implementation;

FIG. 7 is cross section exploded view of a collet and drill guide,according to an implementation;

FIG. 8A-8C are cross sectional views of a collet sealing the drill bit,according to an implementation;

FIG. 8D is a complete system of FIG. 3 with the inclusion of drill guideattachments, according to an implementation;

FIG. 9 is an isometric view of an injection system with two gates,according to an implementation;

FIG. 10 is an isometric view of an injection system with one gate,according to an implementation;

FIG. 11 is a flow chart of a valve repair method that uses the injectionsystem of FIG. 6 , according to an implementation;

FIG. 12 is a flow chart of a valve repair method that uses the injectionsystem of FIG. 6 , according to an implementation;

FIG. 13 is a flow chart of a valve repair method that uses the injectionsystem of FIG. 6 , according to an implementation;

FIG. 14 is a flow chart of a valve repair method that uses the injectionsystem of FIG. 6 , according to an implementation;

FIG. 15 is a flow chart of a valve repair method that uses the injectionsystem of FIG. 9 , according to an implementation;

FIG. 16 is a flow chart of a valve repair method that uses the injectionsystem of FIG. 10 , according to an implementation;

FIG. 17 is a block diagram of a clamp that is operable to secure thefriction bonding actuator and motor to the valve while the boss is beingbonded to the valve, force being provided by a pressure pump, accordingto an implementation;

FIG. 18 is a block diagram of a clamp that is operable to secure thefriction bonding actuator and motor to the valve while the boss is beingbonded to the valve, force being provided by a hand crank, according toan implementation;

FIG. 19 is a cross section diagram of a chain pipe clamp, according toan implementation;

FIG. 20 is a block diagram of a top view of a strap clamp, according toan implementation;

FIG. 21 is a block diagram of a side view of a magnet clamp being usedon a large pipe, according to an implementation;

FIG. 22 is cross section block diagram of a top view of the magnet clampshown in FIG. 21 , according to an implementation;

FIG. 23A is an isometric diagram and 23B is a cross section diagram of arepaired pipe using a metal patch, according to an implementation;

FIG. 24A is an isometric diagram and 24B is a cross section diagram of arepair plate that uses a channel gasket, according to an implementation;

FIGS. 25A and 25B are cross section diagrams of a plate that ispre-warped to mismatch the curvature of a pipe, according to animplementation;

FIG. 26A is an isometric diagram and 26B is a block diagram of a platethat is pre-warped with a gradient to alter the location of the maximumpressure on the pipe to enhance sealing at the defect area, according toan implementation;

FIG. 27A is an isometric diagram and 27B is a cross section diagram of ablock patch used to add more pressure at a defect area of a pipe toenhance sealing of the defect, according to an implementation;

FIG. 28A is a cross section diagram and 28B is a cross section diagramof a block patch with tensioners, according to an implementation;

FIG. 29 is cross section diagram of a block patch with adjusters,according to an implementation;

FIG. 30 is a cross section diagram of portable friction forge bonder(PFFB) with studs being used to secure a walkway to a pipe, according toan implementation;

FIG. 31 is a cross section diagram of a portable friction forge bonderused to attach cathodes for cathodic protection systems on pipelines,according to an implementation;

FIG. 32 is a cross section diagram of a large 2″ fitting attached fortesting of chemicals in a pipe, testing of the environment outside thepipe or both, according to an implementation;

FIG. 33 is a block diagram of a portable friction forge bonder,according to an implementation;

FIG. 34 is a cross sectional drawing of a preferred embodiment of theactuator, according to an implementation;

FIG. 35 is the cross sectional drawing of another embodiment of theactuator, according to an implementation

FIG. 36 is an isometric diagram of a boss or Permanent UniversalReceiver (PUR) attached through friction welding to an in-service pipe,pressure component or a valve, according to an implementation;

FIGS. 37A and 37B are an isometric drawing of a PUR or boss that isbonded to a work surface through friction welding and subjected to alateral force at the top of the PUR or boss, according to animplementation;

FIG. 38 is PUR or boss that has been attached to a work surface and isthreaded with a tapered thread such as a National Pipe Thread (NPT),according to an implementation;

FIG. 39 is a very low profile boss or PUR that is solid-state welded toa work piece, the PUR for receiving a threaded stud and jam nut which isscrewed into a chuck, according to an implementation;

FIG. 40 is a cross section side view of the very low profile boss inFIG. 39 , according to an implementation having internal threads on thevery low profile boss;

FIG. 41 is a cross section side view of the very low profile boss inFIG. 39 , according to an implementation having external threads on thevery low profile boss;

FIG. 42 is a cross section side view of the very low profile boss inFIG. 39 , according to an implementation;

FIG. 43 is cross section side-view of a leak sealed gate valve,according to an implementation;

FIG. 44 is a cross section side-view of a leak sealed globe valve,according to an implementation;

FIG. 45 is a cross section side-view of a leak sealed ball valve,according to an implementation;

FIG. 46 is a cross section diagram of a pipe flange leak seal, accordingto an implementation;

FIG. 47 is an isometric cross section diagram of the pipe flange leakseal of FIG. 46 , according to an implementation;

FIG. 48 is an isometric cross section view of a pipe union leak seal,according to an implementation;

FIG. 49 is a cross section diagram of a line-kill with valve, accordingto an implementation;

FIG. 50 is a cross section diagram of a threaded pipe leak seal withthreaded pipe end-cap, according to an implementation;

FIG. 51 is a cross section diagram of a pipe line kill using a crimp andsealant, according to an implementation;

FIG. 52 is a cross section diagram of a pipe line kill using two crimpsand sealant according to an implementation;

FIG. 53 is an isometric diagram of a non-perpendicular friction weldedstud, boss or PUR, according to an implementation;

FIG. 54 is a cross section diagram of a ball and spring check valveisolation gate, according to an implementation;

FIG. 55A and FIG. 55B are cross section diagrams of a flapper checkvalve isolation gate, according to an implementation;

FIG. 56 is a cross section diagram of an apparatus for measuring,sensing and/or controlling stud or PUR displacement during the frictionwelding process, according to an implementation;

FIG. 57 is side-view diagram of an ultrasonic enhanced friction welder,according to an implementation;

FIG. 58A is an injection port skirt for receiving an isolation gate toseal the valve, according to an implementation;

FIG. 58B is an isometric view of an injection port skirt for receivingan isolation gate to seal the valve, according to an implementation;

FIG. 59 is an isometric cross section view of a sealant cage forproviding more space for injected sealant during a valve leak repair,according to an implementation;

FIG. 60 is side view cross section block diagram of a valve thatcontains a sealant cage, according to an implementation;

FIG. 61 is a cross section view of one-half of a pipe flange or valveflange with injection ports, according to an implementation;

FIG. 62A is a cross section view of an injectable flange gasket,according to an implementation;

FIG. 62B is an isometric view of an injectable flange gasket, accordingto an implementation;

FIG. 63 is an isometric view of a threaded cup containment device foradding a backup seal for the isolation gate, according to animplementation;

FIG. 64A is an isometric diagram of a multi-motor drive system fordoubling the drive capability of a portable friction welding system,according to an implementation;

FIG. 64B is a bottom view block diagram of a multi-motor drive systemfor doubling the drive capability of a portable friction welding system,according to an implementation;

FIG. 65 is a block diagram of a multi-motor drive system for doublingthe drive capability of a portable friction welding system, according toan implementation.

DETAILED DESCRIPTION OF THE DRAWINGS

The detailed description below describes methods and apparatus forrepairing and sealing of valves, pipes and pipe components.

The numerous innovative teachings of the present application will bedescribed with particular reference to the exemplary embodiments.However, it should be understood that this class of embodiments providesonly a few examples of the many advantageous uses of the innovativeteachings herein. In general, statements made in the specification ofthe present application do not necessarily limit any of the variousclaimed inventions. To the contrary, the description of the exemplaryembodiments are intended to cover alternative, modifications, andequivalents as may be included within the spirit and scope of theinvention as defined by the claims. Moreover, some statements may applyto some inventive features but not to others.

FIG. 1 is an isometric diagram of a valve 100, according to animplementation. Valve 100 is used in refineries, factories, publicutilities, maritime, office buildings, pharmaceuticals, food processing,pipeline transportation and storage, offshore, mining, power and manyother areas. In some implementations the valve 100 is a conventionalgate valve.

FIG. 2 is a cross section diagram of the valve 100 in FIG. 1 , accordingto an implementation. The portions referenced in the disclosure are thegland packing 216, gland follower 214, stem 208 and the gland followerretaining nuts 212. The gland packing 216 seals the stem 208 fromleakage and the gland follower 214 compresses the gland packing 216 whenthe gland follower retaining nuts 212 are tightened.

Valve 100 includes a wheel nut 202 that is operably coupled to a handwheel 204 and a stem nut 206. The stem nut 206 is operably coupled to astem 208. The stem 208 is operably coupled to a gland flange 210 and thegland flange 210 is operably coupled to gland follower retaining nuts212. The gland flange 210 is operably coupled to a gland follower 214.Gland follower 214 is operably coupled to a gland packing 216. The glandpacking 216 is operably coupled to a back seat 218. The back seat 218 isoperably coupled to a bolt-nut 220. The bolt-nut 220 is operably coupledto a bonnet 222. The bonnet 222 is operably coupled to gasket 224. Thegasket 224 is operably coupled to a wedge (gate) 226. The wedge (gate)226 is operably coupled to a valve seat 228. The valve seat 228 isoperably coupled to a body 230.

In some gate valves, stem 208 will have a partial outer thread (notshown in FIG. 2 ) and a yoke 232 and/or stem nut 206 will have an innerthread (not shown in FIG. 2 ). When hand wheel 204 is rotated, thethreads are activated and the stem places an upward or downward force onthe wedge (gate) 226 to open or close the valve.

FIG. 3 is a system 300 with an injection system that is aligned with avalve, according to an implementation. System 300 includes injectionsystem 302. The injection system 302 is operably coupled to a hose 304.The hose 304 is operably coupled to an injection pump 306. The injectionjump 306 has a pressure gauge 308. System 300 includes a valve 100, thevalve 100 includes a stem 208, gland follower 214, a gland packing 216,a weld joint 310, and a boss 312. A drill bit 314 of a drill 316 entersthe injection system 302. In system 300, the boss 312 is attached to thevalve 100. The injection pump 306, the drill 316 and the drill bit 314combined with the injection system 302 complete the repair system.Subsequent figures demonstrate the use of the system 300 for repairingvalves without the release of hazardous chemicals from the valve 100into the atmosphere.

FIG. 4 is an exploded isometric view of an injection system 400,according to an implementation. Injection system 400 is oneimplementation of injection system 302 in FIG. 3 . Three gates 406, 408and 410 are used to route the flow of sealant under pressure throughoutthe injection system 400. O-rings provide a seal for each gate. A collet402 is used to seal the opening when a drill bit is inserted. Theisolation gate 410, the injection gate 408 and the drill guide 404 arethreaded for assembly purposes. Clip rings hold the isolation gate 410in place and allow them to rotate freely.

The collet 402 is operably coupled to a drill guide 404. The drill guide404 is operably coupled to a drill guide gate 406. The drill guide gate406 is operably coupled to an injection gate 408 and to an isolationgate 410. The isolation gate 410 is operably coupled to a boss 312. Thedrill guide gate 406 includes a gate stem 412. The injection gate 408includes a gate stem 414. The isolation gate 410 includes a gate stem416.

The boss 312 can be attached using friction forge bonding or any otherattachment apparatus that eliminates possible ignition sources. Theinjection system 400 is maintained under pressure during a portion ofthe drilling process, so that when the drill bit 314 penetrates thevalve 100, hazardous chemicals or other materials are contained insidethe valve 100 or inside injection system 302, which provides valverepair with zero hazardous emissions, but also zero emissions of anytype. The drill bit 314 to collet seal plus all three gates 406, 408 and410 are sealed with sealant, preventing any possible leakage, whichprovides valve repair with zero emissions.

In some implementations, the injection system is pressure tested beforedrilling through a wall of the valve 100. During this testing, muchhigher pressures that what is typically needed to maintain positivepressure (about 3,000 to 5,000 psi) can be used to test theboss-to-valve attachment. This pressure testing serves to seal the gates406, 408 and 410 and collet 402 as well. Also, injection system 400takes fewer steps to test than conventional systems, which providesvalve repair with zero emissions. The isolation gate 410 can berotationally oriented for convenience and clearance and is more compactthan the conventional systems. To inject the valve 100 after a firstinjection into valve 100, the injection system 400 is not needed;instead a pressure pump can be attached to the isolation gate 410 andre-injection performed through the isolation gate 410. If the isolationgate 410 freezes closed due to corrosion or damage, the frozen isolationgate 410 can be replaced with a new isolation gate 410 or a newisolation gate 410 can be screwed into the frozen isolation gate 410 andthe frozen isolation gate 410 can be drilled through.

FIG. 5 is a cross sectional isometric view of the injection system 400shown in FIG. 4 , according to an implementation. The injection system400 includes a drill guide gate 406, an isolation gate 410 attached tothe drill guide 404 and an injection gate 408 attached to the drillguide 404. An end of the drill guide 404 is not attached to theisolation gate 410. The end includes a collet 402. In someimplementations of the injection system 400, the drill guide gate 406includes a junction having a first passageway 418 and a secondpassageway 420, the second passageway 420 intersecting the firstpassageway 418 at an intersection 424, each of the passageways having afirst end and a second end. In some implementations of the injectionsystem 400, the first passageway 418 includes a first gate stem 412 inwhich the first gate stem 412 is positioned between the second end ofthe first passageway 418 and the intersection 424. In someimplementations of the injection system 400, the second passageway 420includes a second gate stem 414 in which the second gate stem 414 ispositioned between a second end of the second passageway 420 and theintersection 424. In some implementations of the injection system 400,the first end of the first passageway 418 has a complimentary interfaceto the isolation gate 410. In some implementations of the injectionsystem 400, the second end of the second passageway 420 has acomplimentary interface to the injection gate 408. In someimplementations of the injection system 400 (not shown), the firstpassageway 418 includes a gate stem 412 between the second end of thesecond passageway 420 and the intersection 424. In some implementationsof the injection system 400, the drill guide gate 406 is attached to theisolation gate 410 and the injection gate 408 through complimentarymale-female interfaces. In some implementations of the injection system400, the drill guide gate 406 is attached to the isolation gate 410 andthe injection gate 408 through threaded interfaces. In someimplementations of the injection system 400, each of the drill guidegate 406, the isolation gate 410 and the injection gate 408 includes agate stem. In some implementations of the injection system 400, thedrill guide gate 406 includes a gate stem 412. In some implementationsof the injection system 400, the isolation gate 410 includes a gate stem416. In some implementations of the injection system 400, the injectiongate 408 includes a gate stem 414.

FIG. 6 is an isometric view of an assembled injection system 400 of FIG.4 , according to an implementation. The position of the gates can becontrolled by a hex wrench. The collet 402 is operably coupled to adrill guide 404. The drill guide 404 is operably coupled to a drillguide gate 406. The drill guide gate 406 is operably coupled to aninjection gate 408 and to an isolation gate 410. The isolation gate 410is operably coupled to a boss 312.

FIG. 7 is cross section exploded view 700 of a collet and drill guide,according to an implementation. A seal 702, a threaded collet 402 and adrill bit 314 are all shown. After the drill bit 314 is inserted intothe collet 402, through the seal 702 and into the drill guide 404, thecollet 402 is screwed into the drill guide 404 with the threads 704.Tightening the collet 402 against the seal 702 compresses the seal 702around the drill bit 314. The seal 702 prevents sealant from leakingpast the drill bit 314. If pressure in the drill guide 404 is too large,however, the drill bit 314 can be forced out of the collet 402. FIG. 7includes a collet 402 that is operably coupled to seal 702 and a thread704. The drill bit 314 is inserted into a collet 402 and a seal 702, anda drill guide 404.

FIG. 8A-8C are cross sectional views 800A, 800B and 800C of a colletsealing the drill bit, according to an implementation. In addition tothe collet in FIG. 7 , a stop is attached to the drill bit to preventpressure from forcing the drill bit out of the drill guide 404.

FIG. 8A includes a collet 402 that has threads 704 and that is operablycoupled to a seal 702. The drill bit 314 is inserted into the collet 402and the seal 702, and a drill guide 404. A stop 802 having a set screw804 and a gasket 806 is operably coupled to the drill bit 314 on theopposite side of the collet 402 from the drill 316.

FIG. 8B includes a collet 402 that has threads 704 and that is operablycoupled to a seal 702. The drill bit 314 is inserted into the collet 402and the seal 702, and a drill guide 404. A stop 802 having a set screw804 is operably coupled to the drill bit 314 between the collet 402 andthe drill 316.

FIG. 8C includes a collet 402 that has threads 704 and that is operablycoupled to a seal 702. A sliding drill support 808 having a drill guideattachment 807 is fixedly attached to a drill guide 404 by securingbolts 808. A drill clamp 810 is operably coupled to the sliding drillsupport 808 and the drill guide attachment 807. The drill bit 314 isinserted into the drill clamp 810, the sliding drill support 806, thecollet 402 and the seal 702, and the drill guide 404. The sliding drillsupport 808 also includes stops 812 and set screws 814.

FIG. 8D is system 800D of FIG. 3 with the inclusion of drill guideattachments, according to an implementation. FIG. 8D includes atelescoping support with extension stop 816 that is fixedly attached toa valve 100. A drill clamp 810 is operably coupled to the drill guideattachment 807. A drill guide attachment 807 is a sliding drill support808 and the drill guide attachment 807 is a part of the telescopingsupport with extension stop 816. A drill clamp 810 is operably coupledto the telescoping support with extension stop 816. The drill bit 314 isinserted into the drill clamp 810, the drill guide attachment 807 andtelescoping support with extension stop 816 in the injection system 302.The telescoping support with extension stop 816 also includes stops 812and set screws 814. The injection system 302 is operably coupled to ahose 304. The hose 304 is operably coupled to an injection pump 306. Theinjection jump has a pressure gauge 308. FIG. 8D includes a valve 100.The valve 100 includes a stem 208, gland follower 214, a gland packing216, a weld joint 310, and a boss 312. The telescoping support withextension stop 816 is attached to the valve 100 by clamps 820.

In one example of operating the system 800D, the boss 312 is attachedthrough friction bonding to the valve 100 in line with or near the glandpacking 216, creating the weld joint 310. The boss can be attached usingany type of non-ignition, non-penetrating bonding technique such as:friction welding, inertia welding, ultrasonic bonding, cold bonding,diffusion welding, adhesives or any other attachment apparatus formetal. The packing material used within gland packing 216 is a soft yetfirm, rope-like material that seals chemicals inside the valve 100 fromleaking out. The weld joint 310 can be tested for strength with a torquewrench. The isolation gate 410 is screwed into the threaded end of theboss 312 and the drill guide 404 is screwed into the isolation gate 410.The drill guide gate 406 is part of drill guide 404. The injection gate408 is then screwed into the drill guide 404 and the hose 304 is screwedinto the injection gate 408. The injection pump 306 is attached to hose304. The injection gate 408 is opened and the isolation gate 410 and thedrill guide gate 406 are closed. The injection system 302 is injectedwith sealant at a high pressure between 3,000 psi and 5,000 psi to sealall three gates 406, 408 and 410 and any joints from leakage. Thepressure is held to verify that the injection system 302 is leak free.Subsequently, the isolation gate 410 is opened. Under high pressure fromthe injection pump 306, sealant is injected through the isolation gate410 and into the boss 312. This pressurizes the injection system 302 andtests the quality of injection system 302, including the weld joint 310and the boss 312, before drilling into the valve 100. In anotherimplementation, the two injection actions can be combined into oneaction and the isolation gate is opened before the two injectionactions. Thereafter, the injection gate 408 is closed, stopping the flowof sealant into the injection system 302. The drill bit 314 is insertedinto the drill guide 404 until the drill bit 314 makes contact with thedrill guide gate 406. The collet 402 (not shown in FIG. 8D) is tightenedaround the drill bit 314 to provide a seal and the drill guide gate 406is opened. At this time, a small amount of sealant backs up into drillguide 404 causing pressure in injection system 302 to drop. Through useof a non-sparking pneumatic drill 316, the drill bit 314 is used todrill through the sealant until the drill bit 314 enters the boss 312.The drilling continues until the drill bit 314 penetrates the wall ofthe valve 100 into or near gland packing 216. During the drillingprocess, metal shavings and sealant particles are created and depositedin the space between the drill guide gate 406 and the collet 402 (notshown in FIG. 8D). Also, at the moment that drill bit 314 penetrates thewall of valve 100, pressure inside valve 100 may cause chemicals toenter injection system 302. Before the drill bit 314 is withdrawn fromvalve 100, injection gate 408 is opened and sealant is released into theinjection system 302 to increase the pressure in injection system 302 tobe greater than or equal to the pressure in valve 100. This preventsfurther chemical release from the valve. The drill bit 314 is thenwithdrawn to a point just past the drill guide gate 406. The drill guidegate 406 is then closed. As the drill bit 314 is withdrawn from valve100, sealant passing through injection gate 408 fills the void left bythe drill bit 314. Injection gate 408 can be used to increase ordecrease the flow of sealant into the void left behind in the sealant asthe drill bit 314 is withdrawn. No chemicals are released from the valve100 or the injection system 302 into the environment, because of thepositive pressure (equal to or slightly greater than the pressure invalve 100) in injection system 302. Because the positive pressureprevents any hazardous chemicals from escaping from valve 100 into theatmosphere repair technicians remain safe. An expansion region iscreated in gland packing 216 by loosening the gland follower retainingnuts 212 (see FIG. 2 ). New pliable sealant is injected into glandpacking 216 by opening the injection gate 408 and using injection pump306. During this injection process, chemicals that have entered theinjection system 302 are forced back into valve 100 where they camefrom. Also, some of the metal shavings and sealant particles may beforced into valve 100, but these shavings and particles are small enoughto not create a problem. Once a sufficient amount of sealant is injectedinto the valve 100, the isolation gate 410 is closed. Pressure is thenrelieved from the injection pump 306 and the drill guide 404 is removedfrom the injection system 302. The isolation gate 410 is left attachedto the boss 312 in the closed position, to maintain a seal for the drillhole made by the drill bit in the valve 100. The gland followerretaining nuts are retightened to apply pressure to gland packing 216 toensure a seal on the valve 100. System 800D improves repair techniciansafety during valve and pipe repair by eliminating hazardous chemicalemission from inside the valve 100 or from the injection system 302.System 800D allows pipes and valves to be repaired in a hazardousenvironment because of the elimination of combustible processes and iteliminates atmospheric emissions during the repair process, which isenvironmentally beneficial.

FIG. 9 is an isometric view of an injection system 900 with only twogates, according to an implementation. Two gates 406 and 410 are used toroute the flow of sealant under pressure throughout the system 900.O-rings provide a seal for each gate. A collet 402 is used to seal theopening to the valve 100 when a drill bit is inserted. The isolationgate 410 and the drill guide gate 406 are threaded for assemblypurposes. The collet 402 is operably coupled to a drill guide 404. Thedrill guide 404 is operably coupled to the drill guide gate 406. Thedrill guide gate 406 is operably coupled to an isolation gate 410. Theisolation gate 410 is operably coupled to a boss 312. The drill guidegate 406 includes a gate stem 412. The isolation gate 410 includes agate stem 416. In this implementation, since the injection gate 408 hasbeen eliminated, the injection pump is used to control flow of sealantinto injection system 302 instead of injection gate 408. In this way,system 800D can be used as described above to seal pipes and valveswithout the use of injection gate 408.

FIG. 10 is an isometric view of an injection system 1000 with only onegate, according to an implementation. A gate 410 is used to route theflow of sealant under pressure throughout the system 1000. O-ringsprovide a seal for the gate. A collet 402 is used to seal the opening tothe valve 100 when a drill bit is inserted. The isolation gate 410 isthreaded for assembly purposes. The collet 402 is operably coupled to adrill guide 404. The drill guide 404 is operably coupled an isolationgate 410. The isolation gate 410 is operably coupled to a boss 312. Theisolation gate 410 includes a gate stem 416. In this implementation, thecollet 402 is used to gate the flow of sealant through drill guide 404instead of the drill guide gate 406.

Some implementations of the injection system of FIGS. 3-6 and 9-10include two or more isolation gates 410 and that are all coupledtogether in-line between the boss 312 and the drill guide 404.

FIG. 11 is a flow chart of a valve repair method 1100 that uses theinjection system of FIG. 6 , according to an implementation. In someimplementations, method 1100 includes attaching a boss to a valve, atblock 1102. In some implementations, method 1100 includes attaching aninjection system to the boss, at block 1104. In some implementations,method 1100 includes closing isolation and a drill guide gate andopening an injection gate, at block 1106. In some implementations,method 1100 includes injecting a sealant under pressure into theinjection system, at block 1108. In some implementations, method 1100includes opening an isolation gate, at block 1110. In someimplementations, method 1100 includes injecting the sealant underpressure into the injection system, at block 1112. In someimplementations, method 1100 includes closing the injection gate atblock 1114. In some implementations, method 1100 includes inserting adrill bit into a collet and a drill guide, at block 1116. In someimplementations, method 1100 includes tightening a collet, at block1118. In some implementations, method 1100 includes opening the drillguide gate, at block 1120. In some implementations, method 1100 includesdrilling through the sealant and a valve wall, at block 1122. In someimplementations, method 1100 includes opening the injection gate, atblock 1124. In some implementations, method 1100 includes increasingpressure to be equal to or greater than pressure in the valve, at block1126. In some implementations, method 1100 includes withdrawing thedrill bit and closing the drill guide gate, at block 1128. In someimplementations, method 1100 includes injecting the valve with thesealant, at block 1130. In some implementations, method 1100 includesclosing the isolation gate, at block 1132. In another implementation ofmethod 1100, block 1108 is eliminated.

FIG. 12 is a flow chart of a valve repair method 1200 that uses theinjection system of FIG. 6 , according to an implementation. In someimplementations, method 1200 includes attaching a boss to a valve atblock 1102. In some implementations, method 1200 includes attaching aninjection system to the boss at block 1104. In some implementations,method 1200 includes opening isolation and injection gates and closing adrill guide gate at block 1202. In some implementations, method 1200includes injecting a sealant under pressure into the injection systemand maintaining positive pressure at block 1204. In someimplementations, method 1200 includes inserting a drill bit into acollet and a drill guide at block 1106. In some implementations, method1200 includes tightening the collet at block 1118. In someimplementations, method 1200 includes opening the drill guide gate atblock 1120. In some implementations, method 1200 includes drillingthrough sealant and a valve wall, at block 1122. In someimplementations, method 1200 includes withdrawing the drill bit andclosing the drill guide gate, at block 1128. In some implementations,method 1200 includes injecting the valve with the sealant at block 1130.In some implementations, method 1200 includes closing the isolationgate, at block 1132.

FIG. 13 is a flow chart of a valve repair method 1300 that uses theinjection system of FIG. 6 , according to an implementation. In someimplementations, method 1300 includes attaching a boss to a valve atblock 1102. In some implementations, method 1300 includes attaching aninjection system to the boss at block 1104. In some implementations,method 1300 includes opening isolation, injection, and drill guide gatesat block 1302. In some implementations, method 1300 includes inserting adrill bit into a collet and a drill guide at block 1116. In someimplementations, method 1300 includes tightening the collet at block1118. In some implementations, method 1300 includes pushing the drillbit until it touches the valve at block 1304. In some implementations,method 1300 includes injecting a sealant under pressure into injectionsystem at block 1108. In some implementations, method 1300 includesdrilling through a valve wall at block 1306. In some implementations,method 1300 includes withdrawing the drill bit and closing the drillguide gate at block 1128. In some implementations, method 1300 includesinjecting the valve with the sealant at block 1130. In someimplementations, method 1300 includes closing the isolation gate atblock 1132.

FIG. 14 is a flow chart of a valve repair method 1400 that uses theinjection system of FIG. 6 , according to an implementation. In someimplementations, method 1400 includes attaching a boss to a valve atblock 1102. In some implementations, method 1400 includes attaching aninjection system to the boss at block 1104. In some implementations,method 1400 includes opening isolation, injection, and drill guide gatesat block 1302. In some implementations, method 1400 includes inserting adrill bit into a collet and a drill guide at block 1116. In someimplementations, method 1400 includes tightening the collet at block1118. In some implementations, method 1400 includes pushing the drillbit further until it touches the valve at block 1304. In someimplementations, method 1400 includes injecting a sealant under pressureinto injection system at block 1108. In some implementations, method1400 includes drilling through a valve wall at block 1306. In someimplementations, method 1400 includes withdrawing the drill bit andclosing the drill guide gate at block 1128. In some implementations,method 1400 includes loosening a gland follower retaining nuts at block1402. In some implementations, method 1400 includes injecting thesealant into a gland packing area at block 1404. In someimplementations, method 1400 includes closing an isolation gate at block1132.

FIG. 15 is a flow chart of a valve repair method 1500 that uses theinjection system of FIG. 9 , according to an implementation. In someimplementations, method 1500 includes attaching a boss to a valve, atblock 1102. In some implementations, method 1500 includes attaching aninjection system to the boss, at block 1104. In some implementations,method 1500 includes opening an isolation gate and closing a drill guidegate, at block 1502. In some implementations, method 1500 includesinjecting a sealant under pressure into the injection system, at block1108. In some implementations, method 1500 includes inserting a drillbit into a collet and a drill guide, at block 1116. In someimplementations, method 1500 includes tightening the collet, at block1118. In some implementations, method 1500 includes opening the drillguide gate, at block 1120. In some implementations, method 1500 includesdrilling through the sealant and a valve wall, at block 1122. In someimplementations, method 1500 includes withdrawing the drill bit justenough to close the drill guide gate, at block 1504. In someimplementations, method 1500 includes closing the drill guide gate, atblock 1506. In some implementations, method 1500 includes injecting thevalve with the sealant, at block 1130. In some implementations, method1500 includes closing the isolation gate at block 1132.

FIG. 16 is a flow chart of a valve repair method 1600 that uses theinjection system of FIG. 10 , according to an implementation. In someimplementations, method 1600 includes attaching a boss to a valve, atblock 1102. In some implementations, method 1600 includes attaching aninjection system to the boss, at block 1104. In some implementations,method 1600 includes opening an isolation gate, at block 1110. In someimplementations, method 1600 includes inserting a drill bit into acollet and a drill guide until it contacts the valve, at block 1602. Insome implementations, method 1600 includes tightening the collet, atblock 1118. In some implementations, method 1600 includes injectingsealant under pressure into the injection system at block 1108. In someimplementations, method 1600 includes drilling through the valve, atblock 1306. In some implementations, method 1600 includes withdrawingthe drill bit just past intersection 424, at block 1602. In someimplementations, method 1600 includes injecting the valve with thesealant, at block 1130. In some implementations, method 1600 includesclosing the isolation gate, at block 1132.

FIG. 17 is a block diagram of a clamp 1700 that is operable to securethe friction bonding actuator and motor to a valve while a boss is beingbonded to the valve, force being provided by a pressure pump, accordingto an implementation. The clamp 1700 uses hydraulic pressure to applythe clamping force that holds the clamp 1700 in place. The hydraulicpressure can be applied by several apparatus; the apparatus shown inFIG. 17 is through use of an injection pump 306. The injection pump 306can be used later to inject sealant into the valve 100 for repair. Apressure gauge 308 mounted on the injection pump 306 allows the repairtechnician to monitor the pressure during the valve repair method. Theinjection pump 306 is operably coupled through a hose 304 to a pressurecylinder 1702 that is mounted in a clamp body 1704. The valve 100includes a stem 208 and a body 230. The clamp body 1704 is attached to aforge welder 1706 through a shroud or threaded receiver 1708 and that isoperably coupled to a cylinder of argon gas 1710. The forge welder 1706includes a pneumatic motor and an actuator. The shroud or threadedreceiver 1708 receives the actuator of the forge welder 1706 and shroudsthe weld site with the argon gas 1710. Other gases could be used inplace of argon gas 1710.

FIG. 18 is a block diagram of a clamp 1800 that is operable to securethe friction bonding actuator and motor to the valve while the boss isbeing bonded to the valve, force being provided by a hand crank,according to an implementation. Clamp 1800 uses a hand crank 1802screw-type mechanism to apply a clamping force that holds the clamp body1704 in place. A torque wrench (not shown in FIG. 18 ) can be built intothe crank handle 1704 to apply a precise amount of force needed tosecure the clamp 1704 to the vise. The valve 100 includes a stem 208 anda body 230. The clamp body 1704 is attached to a forge welder 1706 thatincludes the shroud or threaded receiver 1708 and that is operablycoupled to a cylinder argon gas 1710. The shroud or threaded receiver1708 receives the actuator of the forge welder 1706 and shrouds the weldsite with the argon gas 1710. Other gases could be used in place ofargon gas 1710.

FIG. 19 is a cross section diagram of a chain pipe clamp 1900, accordingto an implementation. The chain clamp 1900 is made of a chain 1902(similar to a bicycle chain) and wraps around a pipe 1904. The two ends1906 and 1908 of the chain 1902 connect to the shroud or threadedreceiver 1708. Between the two ends 1906 and 1908 of the chain 1902 is atensioner 1912. One such tensioner 1912 uses a tightening bolt 1914 andtwo flanges. When the bolt 1914 is tightened, the flanges are pulledtogether, tightening the chain clamp 1900. The inside of the shroud orthreaded receiver 1708 is threaded to accept the actuator. The shroud orthreaded receiver 1708 also accepts the argon gas 1710 during thewelding process to eliminate air and thus ensure welding process neverbecomes an ignition source and to improve the quality of the weld.

FIG. 20 is a block diagram of a top view of a strap clamp 2000,according to an implementation. A steel strap 2002 is made of steel andafter being wrapped around the valve 100, the strap 2002 is connected tothe shroud or threaded receiver 1708. Tensioners 2004 allow the steelstrap 2002 to be tightened around the valve 100, holding the shroud orthreaded receiver 1708 against the valve 100. The lever type tensioners2004 are hand activated and adjusted. Any type of tensioner 2004 can beoperable for strap clamp 2000. The shroud or threaded receiver 1708 alsoaccepts the argon gas 1710 during the welding process to prevent thewelding process from becoming an ignition source. Steel strap 2002 couldbe made of cable, chain or any strong flexible material. Strap clamp2000 could be used to secure a shroud or threaded receiver 1708 to apipe or pipe component.

FIG. 21 is a block diagram of a side view of a magnet clamp 2100operable on a large pipe, according to an implementation. Four permanentmagnets 2102, 2104, 2106 and 2108 with disconnects hold a shroud orthreaded receiver 1708 against a pipe 2110 during a friction bondingprocedure. Tensioners 2112, 2114, 2116 and 2118 connecting each magnet2102, 2104, 2106 and 2108 to the shroud or threaded receiver 1708 areemployed to ensure adequate holding force against the pipe 2110. Theactuator, with chuck and boss, are attached to the motor and the shroudor threaded receiver 1708 and held in place during the bonding processby the shroud or threaded receiver 1708.

FIG. 22 is cross section block diagram of a top view of the magnet clamp2100, according to an implementation. The magnet clamp 2100 includes atensioner (2112, 2114, 2116 or 2118) coupled to a magnet (2102, 2104,2106 or 2108) with a release that is coupled to a pipe 2110. Thetensioner (2112, 2114, 2116 or 2118) is rotatably coupled to a shroud orthreaded receiver 1708 that receives a friction bonder 1706. Inert gasis injected into the shroud or threaded receiver 1708 during the bondingprocess. Each tensioner (2112, 2114, 2116 or 2118) is made of a bolt andnut with two flanges. When the bolt is tightened, the flanges are pulledtogether and tension the shroud against the pipe. Other tensioners couldbe used instead of the bolting tensioners shown.

FIG. 23A is an isometric diagram and 23B is a cross section diagram of arepaired pipe 2300 using a metal patch, according to an implementation.A clamp, such as clamp 1900, 2000, 2100 or clamp 2200, is used to securethe friction welder 1706 to a surface of the pipe 2302 to bond a seriesof stud and nuts 2304 to the pipe 2302. A gasket 2306 is then placedover the stud and nuts 2304 followed by a patch 2308. In someimplementations, the gasket 2306 is made of rubber, but in otherimplementations the gasket 2306 is made of any poly compound or softmaterial suitable for a gasket. In some implementations, the patch 2308is made of steel, but in other implementations of the patch 2308 is madeout of any rigid, strong material. The patch 2308 is then pulled tightlyagainst the gasket 2306 and the surface of the pipe 2302 by tighteningthe stud and nuts 2304, which seals the defect 2310 area in the pipe2302.

FIG. 24A is an isometric diagram and 24B is a cross section diagram of arepair plate 2400 that uses a channel gasket, according to animplementation. A channel gasket 2402 is a long round flexible gasketshaped somewhat like a smooth rope that lies in a routed channel 2404routed around the perimeter of the pre-warped plate 2410. In someimplementations, zerts 2406 are added to allow sealant to be injectedinto the routed channel 2404. A simple set screw or bolt could also beused in place of zerts 2406 to close the opening after the routedchannel 2404 is injected with sealant. Though the channel gasket 2402 isshown to be semicircular in shape it is round before installation. Thechannel gasket 2402 could be rectangular, square or any other shape. Aseries of stud and nuts 2304 are attached to the pipe wall 2414 by weldjoints 2412. Stud and nuts 2304 pass through holes 2408 in plate 2410 toattach plate 2410 to pipe wall 2414.

FIGS. 25A and 25B are cross section diagrams 2500 of a plate that ispre-warped to mismatch the curvature of a pipe, according to animplementation. Any pre-warped plate 2410 creates uneven pressure acrossthe entire plate 2410. If the plate 2410 is low-center pre-warped asshown in FIG. 25A, higher pressure 2502 will be created at the center ofthe plate 2410. If the plate 2410 is high-center pre-warped as shown inFIG. 25B, higher pressure 2502 will be created at the edge of the plate2410. By selectively pre-warping the plate a seal with higher integritycan be made at specific locations under the plate 2410.

FIG. 26A is an isometric diagram and 26B is a block diagram of a plate2600 that is pre-warped with a gradient to alter the location of themaximum pressure on the pipe to enhance sealing at the defect area 2310,according to an implementation. FIG. 26B shows topographical lines 2602of a gradient pre-warped plate.

FIG. 27A is an isometric diagram and 27B is a cross section diagram 2700of a block patch used to add more pressure at a defect area of a pipe toenhance sealing of the defect, according to an implementation. A strap2702 is made of a strong yet slightly flexible material such as sheetmetal. A gasket 2704 is placed between the block patch 2706 and the pipe2302. Block patch 2706 could be made of a semi-soft material like hardrubber to eliminate the need for gasket 2704. The strap 2702 is pulledtaught by the studs and nuts 2304 to apply pressure to the block patch2706. The advantage of this type of patch over the pre-warped plate inFIG. 25 and FIG. 26 is that this repair can be prepared and performed onsite. The thickness of block patch 2706 could be of any thickness thatenhances the seal.

FIG. 28A is a cross section block diagram and 28B is a cross sectionblock diagram of a block patch with tensioners 2800, according to animplementation. The patch is similar to the patch is FIGS. 27A and 27B,but with the addition of tensioners 2802 to apply pressure to the blockpatch 2706. A close up of a low-cost implementation of the tensioner2802 is shown in the FIG. 28B, which includes a washer 2804 and a nut2806 that passes through flanges 2808 and are secured to a bolt 2810.The flanges 2808 are secured to the pipe 2302 or the strap 2702 eitherthrough a stud and nut 2304 or a weld 2812. Other tensioners could beused to serve the same purpose.

FIG. 29 is cross section diagram of a block patch with adjusters 2900,according to an implementation. Instead of using tensioners to addpressure to the block patches as shown in FIG. 28A and FIG. 29A,adjusters or tensioning bolts 2902 through a threaded hole or nut 2904can be screwed or tightened against the block patch 2706 to applypressure. Studs 2904 are standard friction bonded studs and do notrequire slotted holes drilled in the strap 2702.

FIG. 30 is a cross section diagram of portable friction forge bondedstuds being used to secure a walkway to a pipe 3000, according to animplementation. Studs 3002 are first attached to the pipe 2302, thenwalkway brackets 3004 are installed. Once the brackets 3004 areinstalled the walkways 3006, such as Grip Strut, are bolted to thebrackets 3004. The brackets 3004 could also be pre-welded to the GripStrut walkways 3006. Ladders (not shown in FIG. 30 ) could be attachedto vertical pipes in the same way even if volatile material is flowingin the pipe 2302.

FIG. 31 is a cross section diagram of a cathodic protected pipe 3100where a portable friction forge bonder (PFFB) attaches cathodes forcathodic protection on pipelines, according to an implementation. Acathodic protected pipe includes cathodic protection electronics 3102coupled via a wire 3104, a friction welded stud 3106 and nuts 3108 thatacts as a cathode. A portable friction forge bonded stud is a betterelectrical contact than drill and tap and is much stronger and lesslikely to break off from accidental impact. A friction welded cathode isalso less likely to corrode over time.

FIG. 32 is a cross section diagram of a large 2″ fitting attached fortesting or sampling chemicals or conditions in a pipe 3200, testing ofthe environment outside the pipe or both, according to animplementation. A hole 3202 is drilled in the pipe 2302 using the repairsystem shown in FIG. 3 . This allows chemicals in the pipe 2302 to besampled or measured. Test equipment 3204 can be mounted to a frictionwelded fitting 3206 or the test equipment 3204 can be cable connected(not shown) or connected to a bracket (also not shown).

FIG. 33 is a block diagram of a portable friction forge bonder (PFFB)3300, according to an implementation. The portable friction forge bonder(PFFB) 3300 includes a pneumatic motor 3302, an actuator 3304 and achuck 3306. A shroud or threaded receiver 1708 allows the PFFB to beconnected to the device being enhanced or repaired. The chuck 3306 holdsand couples the rotational driving force from the motor 3302 and theaxial load force from the actuator 3304, to a boss 3310. The actuator3304 that has threads 3305 applies a predetermined amount of load to thechuck 3306 and the boss 3310 through pressure from a constant pressurehydraulic pump 3311. The motor 3302 derives its power from a high volumeair compressor 3312. The shroud or threaded receiver 1708 bathes theboss 3310 in an inert gas such as argon gas 3314 to eliminate air andthus any possibility of ignition from the welding area and to improvethe quality of the weld. The constant pressure hydraulic pump 3311 isoperably coupled to the actuator 3304 through a hose 3318. The highvolume air compressor 3312 is operably coupled to the pneumatic motor3302 through a hose 3316. The high volume air compressor 3312 can beconnected to the constant pressure hydraulic pump 3311 to provide powerfor the constant pressure hydraulic pump 3311. A hand pump (not shown)could also be used to power constant pressure hydraulic pump 3311.

FIG. 34 is a cross sectional drawing of an actuator 3400, according toan implementation. Constant pressure hydraulic pump 3311 applieshydraulic pressure through hose 3318, through hydraulic port 3414, tothe hydraulic ram 3412 which applies pressure to the thrust bearing 3418which then applies pressure to the drive shaft 3410, which in turnapplies pressure to the chuck 3306 in FIG. 33 and the boss 3310 (boss3310 not shown in FIG. 34 ) in FIG. 33 . Magnet 3422 holds boss 3310 inplace during initial setup of the welding process. The thrust bearing3418 allows drive shaft 3410 to rotate under pressure from hydraulic ram3412 while allowing axial force to be applied to the chuck 3306. Thethreads 3305 hold the actuator 3304 in FIG. 33 to the shroud or threadedreceiver 1708, so that the pressure on the boss 3310 in FIG. 33 istransferred to the valve 100 during friction welding. As the boss 3310in FIG. 33 is driven into the surface of valve 100 during the weldingprocess, the constant pressure hydraulic pump 3311 in FIG. 33 , and thepiston 3402 with hydraulic ram 3412 absorbs the spatial difference. Themounting 3320 in FIG. 33 is an attachment apparatus between thepneumatic motor 3302 in FIG. 33 and actuator 3304 in FIG. 33 . A driveshaft 3410 is inserted into a rear body 3404 of the actuator 3400 thatincludes a motor drive adapter 3406 and bearings 3408. The motor driveadapter 3406 is operably connected to a drive shaft 3410 which isoperably connected to a hydraulic ram 3412. The rear body 3404 includesa hydraulic port 3414 and motor mounting holes 3415 (a portion ofmounting 3320 in FIG. 33 ). A front body 3416 is operably connected tothe rear body 3404, and contains bearings 3408, a thrust bearing 3418, amotor drive adapter 3406 and a magnet 3422. The front body 3416 alsoincludes O-ring 3424 that seals to a shroud or threaded receiver 1708such as a hydraulic clamp 1700 and the front body 3416 includes threads3426 to connect to the shroud to a threaded receiver 1708. Chuck 3306 inFIG. 33 is shown to protrude from actuator 3304 in FIG. 33 and chuck3306 in FIG. 34 is shown to be contained within actuator 3400. These aretwo different implementations that perform the same function.

FIG. 35 is the cross sectional drawing of an actuator 3500, according toan implementation. Actuator converts spring force into force on thepiston 3402 which in turn applies a force to the chuck 3306 in FIG. 33and the boss 3310 in FIG. 33 . The threads 3305 hold the actuator 3500to the clamping device, so that the force on the boss 3310 in FIG. 33 istransferred to the valve 100 during friction welding. The compressedspring 3502 maintains constant pressure on the piston 3402. As the boss3310 in FIG. 33 is driven into the surface of valve 100 during thewelding process, the compressed spring 3502 and piston 3402 absorb thespatial difference. The mounting holes 3415 (a portion of mounting 3320in FIG. 33 ) provide an attachment apparatus for the pneumatic motor. Adriveshaft is inserted into a rear body 3404 of the actuator 3500 thatincludes a motor drive adapter 3406 and bearings 3408. The motor driveadapter 3406 is operably connected to a drive shaft 3410 and passesthrough a compressed spring 3502, piston 3402 and thrust bearing 3418.The rear body 3404 includes motor mounting holes 3415. A front body 3416is operably connected to the rear body 3404, and contains bearings 3408,a thrust bearing 3418, a chuck 3306 and a magnet 3422. Magnet 3422 holdsboss 3310 in place during initial setup for a weld process. The frontbody 3416 also includes O-ring 3424 that seals to a shroud or threadedreceiver 1708 such as a chain clamp 1900 and the front body 3416includes threads 3426 to connect to the shroud to a threaded receiver1708. Different strength springs can be used to vary the axial forceapplied by the actuator 3500. Also, coaxial springs or smaller springsplaced inside of larger springs can be used to select the axial forceapplied by actuator 500 in smaller increments.

FIG. 36 is an isometric diagram of a boss 312 or Permanent UniversalReceiver (PUR) attached through friction welding, also known assolid-state joining or friction bonding, to an in-service pipe (flowcomponent), pressure component or a valve, according to animplementation. Friction welding is also known as solid-state joining orfriction bonding. Friction welding has superior qualities to other typesof welding, joining or bonding such as; lower temperature, spark-free,welding of dissimilar metals and materials, welding under water andwithin liquids, welding in hazardous environments, welding withoutneeding to clean the work surface, higher tensile and sheer strength andhigher torque capacity. The pressure component could contain a positive,negative or ambient pressure. An in-service pipe, pressure component, avalve or other container 3602 may be in or out of service when the PUR312 is being attached however, there is great value in attaching PUR 312while pipe (flow component), pressure component, or valve 3602 isin-service. The PUR 312 is attached to the in-service pipe 3602 byfriction welding the PUR 312 to the in-service pipe 3602 wall, creatinga weld 3606. To gain access to the inside of pipe, pressure component orvalve 3602 or to the contents within it, a hole 3604 may be drilled. Thein-service pressure component 3602 may also be a valve flange or thevalve bonnet. The PUR 312 contains at least one set of threads 3608 forreceiving a multitude of devices, equipment or sensors. Any otherattachment apparatus could be used such as threads, cam locks, unions,flanges, twist locks, clamps or external threads. An internal set ofthreads are shown in FIG. 36 . A second set of outer threads could beadded and used to receive additional devices or to accept a protectivecover for the PUR 312. With a single PUR 312, an unlimited number ofdevices can be designed for attachment to the in-service pipe, pressurecomponent or valve 3602. In repairing valves, the boss or PUR 312receives an injection system 302 as shown in FIG. 3 . This allows thevalve 3602 to be repaired and still allow additional devices orequipment to be attached. For example, a tag indicating repair date orstatus, regulatory body compliance, maintenance tracking information orbar codes can be attached. Sensors for temperature, vibration,acoustics, chemical analysis, radio frequency or strain, for example,could be attached to the PUR 312. Also, sensors that collect datainside, on the surface of or outside pipe, pressure component or valve3602 could be attached to PUR 312. Any type of sensor could be attachedto the PUR 312. The PUR 312 can be attached as a hot tap to pipes tosense, for example, flow rate, temperature, viscosity, pressure,chemical composition, gaseous state, contamination or color. Any hottapping device could be attached to the PUR 312 including a bleeder oran injection port. By using a single PUR 312 to receive any type ofdevice, far more flexibility is achieved allowing for a far greatervariety of uses and since fewer PUR designs can meet many needs, thecost could potentially be lower. In addition, custom or industrystandard equipment, devices or sensors can be installed in the PUR 312.

FIGS. 37A and 37B are isometric drawings of a PUR or boss that is bondedto a work surface through friction welding and subjected to a lateralforce at the top of the PUR or boss, according to an implementation. ThePUR 3702 in FIGS. 37A and 37B has a shaft 3704 that is weaker and moreflexible than the weld 3706 or the work surface 3708, allowing a bendingof the shaft 3704 to occur when a lateral force is applied as shown inthe bottom drawing. The shaft 3704 prevents the weld 3706 or the worksurface 3708 from being damaged, protecting the technician and theenvironment from hazardous chemical release. Standard stainless steel isused to manufacture the PUR 3702, however, any metal can be used thatprovides the above mentioned advantages. Generally, a softer metal usedto manufacture the PUR 3702, will provide more stress relief. Anadditional advantage of using a softer metal to manufacture the PUR 3702is that a softer metal generates less heat in the welding process andreduces the temperature at the backside of the work surface 3708. Thisreduction in temperature provides more safety and less alteration of thechemicals in contact with the backside of the work surface 3708.

FIG. 38 is an isometric cross section drawing of a PUR or boss that hasbeen attached to a work surface by friction welding or bonding, orsolid-phase or solid-state welding and is threaded with a tapered threadsuch as a National Pipe Thread (NPT) 3800, according to animplementation. The PUR or boss 3802 is attached to a work surface byfriction welding or bonding, or solid-phase or solid-state welding tocreate a weld 3804 between the PUR or boss 3802 and a work piece 3806.The PUR or boss 3802 receives an isolation gate 410 that has a taperedthread 3808 providing a better seal and better resistance to vibration,temperature cycling and leakage than non-tapered threads.

FIG. 39 is an isometric drawing of a very low profile boss or PUR thatis solid-state welded to a work piece, the PUR for receiving a threadedstud and jam nut which is screwed into a chuck, according to animplementation. A threaded stud 3902 and jam nut 3904 are used tooperably couple the PUR 3906 to the chuck (not shown in FIG. 39 ) duringthe solid-state welding process. As the chuck is rotated by the motorand actuator (not shown in FIG. 39 ), the threaded stud 3902 transfersthis rotational energy to the PUR 3906. Once the PUR 3906 is bonded tothe work piece 3908 by a friction weld 3910, the jam nut 3904 andthreaded stud 3902 are loosened from a threaded hole 3912 in the PUR3906 and the threaded stud 3902 and jam nut 3904 are removed from boththe chuck and the PUR 3906. A second jam nut (not shown) could be usedto lock the stud into the chuck. Any number of bonding techniques can beused to attach the PUR 3906 to the work piece 3908. The work piece 3908can be a pressure component, a pipe or a valve. The PUR 3906 allowsinstallation in environments where mechanical interference is an issue.

FIG. 40 is a cross sectional side view of the very low profile boss inFIG. 39 , according to an implementation having internal threads on thevery low profile boss. The very low profile boss or PUR 3906 is shownfriction welded to a valve wall 4002 with a hole 4004 drilled throughthe valve wall 4002. The hole 4004 in the valve wall 4002 is drilledwith a narrower diameter than inner threads 4006 of the PUR 3906 toensure that during the drilling process, the inner threads 4006 of thePUR 3906 are not damaged. To prepare for the friction welding process,the stud 3902 is screwed into the PUR 3906 and the jam nut 3904 istightened against the PUR 3906 to prevent the stud 3902 from extendingbeyond the lower edge of the PUR 3906 which prevents the stud 3902 frominterfering with the valve wall 4002 during the friction weldingprocess. If the stud 3902 is not long enough to bottom out in the chuck4008 or if the chuck 4008 does not have a stop for the stud 3902, then asecond jam nut (not shown) can be added and tightened against the bottomof the chuck 4008. Any kind of thread (course thread or a fine thread)could be used for the stud 3902 and the PUR 3906. The chuck 4008 doesnot have to be threaded, but could be any type of chuck 4008 that couldhold the stud 3902 during friction welding. The stud 3902 does not haveto be threaded at its top if the chuck 4008 is capable of holding thestud 3902 without threads. Also shown in FIG. 40 is the weld flash andpenetration zone 4010 from the friction weld 3910 in FIG. 39 .

FIG. 41 is a cross sectional side view of the very low profile boss inFIG. 39 , according to an implementation having external threads on thevery low profile boss. The very low profile boss or PUR 4102 havingexternal threads for receiving an optional thread protector ring or anyapparatus is shown friction welded to a valve wall 4002 with a hole 4004drilled through the valve wall 4002. The external threads of the verylow profile boss or PUR 4102 can be used to receive a secondary sealingcap (similar to that in FIG. 63 , but with the threads on the inside ofthe cap and outside of the PUR), sensors, test equipment, valves, gates,handles, walkway or ladder supports, tags, bar codes, lighting, drillsupports, tools and/or antennas. The hole 4004 in the valve wall 4002 isdrilled with a narrower diameter than inner threads 4006 of the PUR 4102to ensure that during the drilling process, the inner threads 4006 ofthe PUR 4102 are not damaged. To prepare for the friction weldingprocess, the stud 3902 is screwed into the PUR 4102 and the jam nut 3904is tightened against the PUR 4102 to prevent the stud 3902 fromextending beyond the lower edge of the PUR 4102 which prevents the stud3902 from interfering with the valve wall 4002 during the frictionwelding process. If the stud 3902 is not long enough to bottom out inthe chuck 4008 or if the chuck 4008 does not have a stop for the stud3902, then a second jam nut (not shown) can be added and tightenedagainst the bottom of the chuck 4008. Any kind of thread (course threador a fine thread) could be used for the stud 3902 and the PUR 4102. Thechuck 4008 does not have to be threaded, but could be any type of chuck4008 that could hold the stud 3902 during friction welding. The stud3902 does not have to be threaded at its top if the chuck 4008 iscapable of holding the stud 3902 without threads. Also shown in FIG. 40is the weld flash and penetration zone 4010 from the friction weld 3910in FIG. 39 .

FIG. 42 is a cross sectional side view of the very low profile boss inFIG. 39 , according to an implementation. The very low profile boss orPUR 4102 is shown friction welded to the valve wall 4002 with the hole4004 drilled through the valve wall 4002. The hole 4004 in the valvewall 4002 is drilled with a narrower diameter than the inner threads4006 of the PUR 4102 to ensure that during the drilling process, theinner threads 4006 of the PUR 4102 are not damaged. The hole 4004 isusually drilled after PUR 3906 is bonded to valve wall 4002. To preparefor the friction welding process, the stud 3902 is screwed into the PUR4102 and the jam nut 3904 is tightened against the PUR 4102 to preventthe stud 3902 from extending beyond the lower edge of the PUR 4102. Thisprevents the stud 3902 from interfering with the valve wall 4002 duringthe friction welding process. If the stud 3902 is not long enough tobottom out in the chuck 4008 or if the chuck 4008 does not have a stopfor the stud 3902, then a second jam nut (not shown) can be added andtightened against the bottom of the chuck 4008. Any kind of thread(course thread or a fine thread) could be used for the stud 3902 and thePUR 4102. The chuck 4008 does not have to be threaded, but could be anytype of chuck 4008 capable of holding the stud 3902 during frictionwelding. The stud 3902 does not need to be threaded at the top if thechuck 4008 is capable of holding the stud 3902. Also shown in FIG. 42 isthe weld flash and penetration 4010 from the friction weld. The PUR 4102is shown with outer threads that can be used for any number ofattachments such as a protective cap, a mount for a threaded receiver ora tag or bar code indicating the repair date or status and particularsof the repair. An optional thread protector ring 4104 is shown and isused to protect the threads from damage. A set screw 4206 is insertedinto the PUR 4102 after the hole 4004 is drilled through the valve wall4002 to prevent chemical from leaking out of the valve after the valverepair or valve sealing is complete. Though a threaded seal may be farmore reliable than other types of seals, it is not considered apermanent seal and can eventually leak. To eliminate this leak source, awelded cap 4208 is shown in FIG. 42 . After the set screw 4206 isinserted into the PUR 4102, the welded cap 4208 is attached to the PUR4102 by friction welding, creating a seal that is considered to bepermanent. To friction weld the welded cap 4208 to the PUR 4102, thestud 3902 and jam nut 3904 are inserted into the welded cap 4208 toprepare for the friction welding process as before. If access to thehole 4004 is desired at a future time, a hand tool, machine tool orhand-held machine tool can be used to cut the welded cap 4208 away fromthe PUR 4102. The drilling of the hole 4004 in the valve wall 4002 andthe insertion and removal of the set screw 4206 can be accomplishedwhile contained in an injection system to prevent leakage of chemicalsinto the atmosphere. The welded cap 4208 can be welded to the PUR 4102using any other welding or bonding technology other than frictionwelding.

FIG. 43 is cross sectional side-view of a leak sealed gate valve 4300,according to an implementation. A boss or PUR 4302 is friction welded orbonded to the body 230 of the leak sealed gate valve 4300 as shown.Through use of injection system 302, a hole is drilled through the body230 wall and into the cavity next to valve seat 228. The cavity iscircumferential to the wedge gate 226 such that when sealant 4304 isinjected into the boss or PUR 4302, the sealant 4304 fills thecircumferential cavity 4306 as shown. If too much sealant 4304 isinjected into the boss or PUR 4302, the hollow area 4308 surrounding thelower valve stem 4310 will be filled, preventing the wedge gate 226 fromrising and thus the leaked sealed gate valve 4300 from opening. Thistype of seal only works while the leak sealed gate valve 4300 is in theclosed position. Since gate valves are designed to be either fullyopened or fully closed, this does not pose a problem. If the leak sealedgate valve 4300 is sealed while it is closed as shown in FIG. 43 and theleak sealed gate valve 4300 is then opened, some or all of the sealant4304 may wash downstream in the valve along with the chemical. If thesealant 4304 is washed from the valve seat 228, then it will have to bere-sealed once the leak sealed gate valve 4300 is closed again.

FIG. 44 is a cross sectional side-view of a leak sealed globe valve4400, according to an implementation. A boss or PUR 4302 is frictionwelded or bonded to the body 230 of the valve 4400 as shown. Through useof injection system 302, a hole is drilled through the body 230 wall andinto the cavity below the valve seat 228. This cavity encompasses to theentire seal such that when sealant 4304 is injected into the boss or PUR4302, the sealant 4304 fills the cavity as shown. The chemical underpressure holds the sealant 4304 in the defect area of the valve seat 228that is leaking. This type of seal only works while the valve 4400 is inthe closed position. If the globe valve is sealed while it is closed asshown in FIG. 44 and the globe valve is then opened, some or all of thesealant 4304 may wash downstream through the valve along with thechemical. This may be unacceptable in situations where downstreamequipment could be damaged or chemical contamination from sealant 4304is unacceptable. If the sealant 4304 is washed from the valve seat 228,then it will have to be re-sealed once the globe valve is closed again.

FIG. 45 is a cross sectional side-view of a leak sealed ball valve 4500,according to an implementation. One or two boss(es) or PUR(s) 4302 arefriction welded or bonded to the body of the valve as shown. Through useof injection system 302, a hole is drilled through each boss or PUR4302, through the valve body wall and into the two cavities 4502 and4504 on either side of the valve ball 4506 next to the valve seats 4508as shown. The two cavities 4502 and 4504 are circumferential to thevalve ball 4506 such that when sealant 4304 is injected into the boss orPUR 4302, the sealant 4304 fills the circumferential cavities 4502 and4504 as shown. Only one boss or PUR 4302 is required if the particularvalve being repaired has a passageway between the left and rightcavities 4502 and 4504. This passageway is dependent on the ball valvemanufacturer's design. If too much sealant 4304 is injected into theboss or PUR 4302, friction from the sealant 4304 could make it difficultto operate the valve. Unlike the gate and globe valves, this type ofseal works well while the valve is in any position. If the valve isoperated after it has been repaired, sealant will unlikely enter thechemical flow 4510.

FIG. 46 is a cross sectional diagram of a pipe flange leak seal 4600,according to an implementation. In this implementation, two bosses orPURs 4302 aid the injection process, one for injection and the other forventing chemicals to prevent vapor lock. Vapor lock could preventsealant from flowing through the sealant cavity. In preparation for thepipe flange repair, a wire or seal clamp 4602 is inserted into thegroove or gap between the two pipe flanges 4604 as shown. The wire orseal clamp 4602 could be made of wire that is very narrow compared tothe flange gap and multiple windings of the wire could be used to closeoff this gap. The wire or seal clamp 4602 could also be made of wirethat is wider than the flange gap and a hammer or other hand tool couldbe used to peen the wire into the gap to close off the gap. The wire orseal clamp 4602 could be made of a specially designed wireclamp that isinserted into the flange gap instead of a wire. Once the wire or sealclamp 4602 is installed, two bosses or PURs 4302 are friction weldedeach to the outer most edge of the flange 4604 in line with a bolt hole4606 on opposite sides of the flange 4604. Using injection system 302,holes are drilled through the flange wall and into the bolt holes 4606that are aligned with each of the two PURs 4302 and each isolation gate410 (not shown) is then closed. One of the drill guides 404 can beremoved from its isolation gate 410 while leaving this isolation gate410 attached to the boss or PUR 4302. A chemical trap or filter 4608 isattached to this isolation gate 410 to collect escaping chemicals duringthe upcoming injection process. Injection pump 306 is used to injectsealant 4610 into the injection system 302 that is still attached to theboss or PUR 4302. At this time, both isolation gates are open. Assealant 4610 is pushed through the injection system 302 and into thecavity created between the wire or clamp 4602 and the gasket 4612, theunwanted chemical that is in this cavity due to the leak is forced outof the cavity into the chemical trap or filter 4608. This makes room forthe sealant 4610 and allows the sealant 4610 to fill the entire cavity.Once the cavity is filled with sealant 4610, both isolation gates areclosed and the drill guide 404 is removed. If the amount of chemicalreleased into the environment during the injection phase is not ofconcern, then the chemical trap or filter 4608 is not necessary.

FIG. 47 is an isometric cross sectional diagram of the pipe flange leakseal of FIG. 46 , according to an implementation. This implementation isidentical to the implementation of FIG. 46 , however, in thisimplementation, only a single boss or PUR 4302 is installed to injectsealant 4610 into cavity between the wire or clamp 4602 and the gasket4612. In this implementation, the gasket 4612 has a defect area 4702that will allow chemical that is trapped in the cavity to be pushed backinto the pipe as sealant 4610 is injected, in which case, then a secondboss or PUR 4302 is not necessary. This works well if there is a singleleak point that can be identified and the boss or PUR 4302 is bondedclose to this single leak point.

FIG. 48 is an isometric cross sectional view of a pipe union leak seal4800, according to an implementation. A pipe union contains a small gapor cavity 4802 against the union defect 4804 that is circumferential tothe union and pipe. A boss or PUR 4302 is friction welded to the unionin line with the cavity 4802 within the union. Using injection system302, a hole is drilled through the wall of the union into the cavity4802. Sealant is then injected into the cavity 4802 and any chemicalthat is in the cavity due to the union defect 4804 will be pushed backinto the pipe through the union defect 4804. If vapor lock occurs duringsealant injection 4806, a second boss or PUR 4302 (not shown in FIG. 48) can be attached to the union in line with the cavity 4802 and used torelieve pressure and allow the chemical to escape. To prevent thechemical from escaping into the environment, a chemical filter or trap(not shown in FIG. 48 ) can be attached to the boss or PUR 4302 tocapture the escaping chemical.

FIG. 49 is a cross sectional diagram of a line-kill with valve 4900,according to an implementation. When the valve seats 4902 are leaking,another way to stop the leakage of chemicals through the valve is tokill the line or pipe that is leading into the valve. One way to do thisis by friction welding a boss or PUR 4302 upstream from the valve,closing the valve and then attaching the injection system 302 to theboss or PUR 4302. A hole is drilled through the pipe wall using theinjection system 302 to contain any leakage during the drilling andsubsequent sealing process. Sealant 4610 is then injected into the pipethrough injection system 302. The pressure from the chemical flow in thepipe will force the sealant 4610 into the defect area of the valve seat4902. This seal is best suited to situations where the valve were not tobe opened again, because chemical will not flow downstream and notdamage sensitive equipment or contaminate the chemicals in process.

Various sealants 4610 can be used for different purposes. Some sealants4610 are clay-like, others are liquid or rope-like and some are polymersthat harden over time, some are resistant to certain chemicals or waterand some are made of Teflon. Some sealants 4610 are hardened with hightemperature or ultraviolet light and others are softened or liquefied athigh temperature. Sealants 4610 can be made of a wide variety ofmaterials such as Teflon, polymers or metals. One sealant 4610 thatwould work well in FIG. 49 is a sealant 4610 that hardens with time.

FIG. 50 is a cross section diagram of a threaded pipe leak seal withthreaded pipe end-cap 5000, according to an implementation. In thisimplementation, the boss or PUR 4302 is friction welded to an end cap5006 to the area located over NPT threads 5002. The injection system 302is then attached to the boss or PUR 4302. A hole is drilled through theend cap 5006 into the threaded region using the injection system 302 tocontain any leakage during the drilling and subsequent sealing process.Sealant 4610 is then injected into the leaking threads 5004 through useof injection system 302. An isolation gate 410 is then closed and drillguide 404 is removed.

FIG. 51 is a cross section diagram of a pipe line kill using a crimp andsealant 5100, according to an implementation. If a segment of a pipe5104 is to be removed from operation while it is in operation, a crimp5102 is made to kill the majority of chemical flow, according to animplementation. Then a boss or PUR 4302 is friction welded to the pipe5104 upstream from the crimp 5102 and injection system 302 is attachedto the boss or PUR 4302. A hole is drilled through the pipe 5104 usingthe injection system 302 to contain any leakage during the drilling andsubsequent sealing process. Sealant 4610 is then injected into the pipe5104 through injection system 302. Pressure from the chemical flowforces sealant into any leaks in the crimp 5102 stopping all flow ofchemical in the pipe 5104. A sealant 4610 that hardens with time may bebeneficial in a crimp and sealant 5100. Though a specific ordering issuggested hereabove for making the crimp 5102, friction welding the bossor PUR 4302 to the pipe 5104 and drilling a hole through the pipe 5104,other orders could be used to successfully perform a pipe line kill.

FIG. 52 is a cross section diagram of a pipe line kill using two crimpsand sealant 5200, according to an implementation. When a segment of pipe5104 is to be removed from operation while the pipe 5104 is inoperation, two crimps 5102 are made to stop (i.e. kill) the chemicalflow through the pipe 5104. Then a boss or PUR 4302 is friction weldedbetween the crimps 5102 and injection system 302 is attached to the bossor PUR 4302. A hole is drilled through the pipe wall 5104 using theinjection system 302 to contain any leakage during the drilling andsubsequent sealing process. Sealant 4610 is then injected between thecrimps 5102 and into the pipe 5104 through injection system 302.Pressure from the sealant seals any leaks in the crimp 5102 stopping allflow of chemical in the pipe 5104. One advantage of this pipe line killimplementation is that leak sealing is independent of chemical pressureand a wider range of sealants would provide an adequate seal.

FIG. 53 is an isometric diagram of a non-perpendicular friction weldedstud, boss or PUR, according to an implementation. Friction weldingrequires that the stud 3002, boss or PUR 3702 to be perpendicular to thesurface during the welding process. To attach a stud 3002, boss or PUR3702 non-perpendicular to the in-service pipe, pressure component orvalve 3602, a notch or wedge 5302 can be cut at an angle that willposition the stud 3002, boss or PUR 3702 at a desirable angle to thepipe, pressure component or valve 3602. This ensures that the stud 3002,boss or PUR 3702 is perpendicular to the weld surface while maintaininga desired angle with the pipe, pressure component or valve 3602. Amodified magnet clamp 5304 is used to hold the actuator 3304, motor 3302and chuck 3306 at the desirable angle during the friction weldingprocess. The notch or wedge 5302 in the work surface must provide enoughclearance to accommodate the chuck 3306, actuator 3304 and motor 3302.Another way to attach a boss or PUR 3702 that is not perpendicular tothe pipe, pressure component or valve 5104 is to first, friction weldthe stud 3702 perpendicular to the pipe, pressure component or valve5104, bend the stud 3002 or boss 3702 to the desired angle using ahammer or hand tool and then attach an angled base 5306 over the stud3002 as shown. Both of these non-perpendicular studs, bosses or PURs3702 can be used to attach devices at any desirable angle.

FIG. 54 is a cross section diagram of a ball and spring check valveisolation gate 5400, according to an implementation. After a boss or PUR4302 is friction welded to a work surface and a hole is drilled throughthe boss or PUR 4302 and the work surface, a ball and spring check valveisolation gate 5400 is attached to the boss or PUR 4302. A work surfacemay be a pipe, a pressure component or valve 3602. The ball 5402 andspring 5404 of the ball and spring check valve isolation gate 5400allows sealant to flow in one direction through the hole in the boss orPUR 4302 and work surface, yet prevents sealant from flowing in theother direction. The ball and spring check valve isolation gate 5400requires the drilling to be performed before the ball and spring checkvalve isolation gate 5400 is attached to the boss or PUR 4302.

FIGS. 55A and 55B are cross section diagrams of a flapper check valveisolation gate 5500, according to an implementation. After a boss or PUR4302 is friction welded to a work surface, the flapper check valveisolation gate 5500 is attached to the boss or PUR 4302. A hole is thendrilled through the PUR 4302 and the wall of the work surface by passingthe drill bit through the flapper check valve isolation gate 5500. Asthe drill bit passed through the flapper check valve isolation gate5500, the flapper 5502 is pushed up and out of the way. The flappercheck valve isolation gate 5500 allows sealant to flow in one directionthrough the hole in the boss or PUR 4302 and work surface, yet preventssealant from flowing in the other direction. Gate seats 5504 form a sealbetween the flapper and gate body of flapper check valve isolation gate5500. Flapper check valve isolation gate 5500 does not require thedrilling to be performed before the flapper check valve isolation gate5500 is attached to the PUR.

FIG. 56 is a cross section diagram of an apparatus 5600 for measuring,sensing and/or controlling stud or PUR displacement during the frictionwelding process, according to an implementation. As a boss or PUR 4302is friction welded to a pipe or pressure component 5606, a portion ofthe bossd or PUR 4302 is consumed by the weld. The consumption causes adisplacement 5604 or reduction in length of the boss or PUR 4302 Also,as the actuator applies pressure to the pipe or pressure component 5606through the boss or PUR 4302, the pipe or pressure component 5606 flexescausing excess displacement 5604. If the pipe or pressure component 5606has thinned due to corrosion or wear such that it is at risk of punchthrough during the welding process, then it is desirable to indicatethis to the operator or to prevent a large pressure from being appliedor a weld from taking place. There is a need to measure or sensedisplacement 5604 of the boss or PUR 4302 in a friction welder. Theapparatus in FIG. 56 includes two apparatus of measuring or sensing thedisplacement 5604 with one apparatus capable of controlling the frictionwelding process based on this displacement 5604. At the top left cornerof FIG. 56 is a viewing port 5612 in rear body 3404. The viewing port5612 exposes the drive shaft 3410. The drive shaft 3410 includesprecision circumferential gradients 5602 that can be seen through theviewing port 5612. The precision circumferential gradients 5602 on driveshaft 3410 can be etched, cut, painted, inked or marked and must beaccurately installed so that they appear relatively stationary as driveshaft 3410 rotates during a friction welding process. The precisioncircumferential gradients 5602 allow the displacement 5604 to bemeasured visually through the viewing port 5612. A crosshair (not shown)could be added in line with the viewing port 5612 to allow more accuratereading of the precision circumferential gradients 5602. In oneapplication, the displacement caused by the actuator pressure on thepipe or pressure component 5606 is measured to determine the thicknessand/or strength of the pipe or pressure component 5606. The pipe orpressure component 5606 thickness and strength are almost always knownand a predetermined displacement will indicate the condition of the pipeor pressure component 5606. If corrosion has thinned the pipe orpressure component 5606 a larger amount of displacement 5604 than thepredetermined amount of displacement 5604 will occur when pressure isapplied by the actuator. In another application, the displacement 5604is measured before and after the friction weld is complete to determinethe amount of displacement 5604 that has occurred during a frictionweld. This measurement can be used as feedback to the operator, allowingthe operator to adjust the welding process to improve it. For example,if excess displacement 5604 occurs during a weld, the operator canreduce the axial pressure on the boss or PUR 4302, reduce the weld timeor reduce the welder's rotational speed.

The apparatus in FIG. 56 includes another apparatus of measuring thedisplacement 5604 and controlling the friction welding process based onthe measured displacement 5604. The apparatus in FIG. 56 , also includesa pneumatic switch 5620 mounted to the body of the actuator through anarm 5608. Above and in line with the pneumatic switch 5620 is a thrustbearing arm 5610 extending off of the thrust bearing 3418 through a port5622 cut in front body 3416. A jam nut 5614 locks the pneumatic switch5620 in position at a predetermined distance from the thrust bearing arm5610. Operably coupled to the pneumatic switch 5620 is a pneumaticcontroller 5616 that controls the welding process. As the thrust bearing3418 is driven downwards, the thrust bearing arm 5610 presses thepneumatic switch 5620 which in turn shuts down the friction weldingprocess. The friction welding process may also be shut down bydisengaging the motor that drives the friction welder. In this way, apneumatic switch 5620 can be used to measure displacement 5604 andcontrol the friction welding process based on the measured displacement5604. The pneumatic switch 5620 may generate a continually variablecontrol signal and the pneumatic controller 5616 may be capable ofreceiving this continuously variable control signal through the hose5618 from the pneumatic switch 5620. In yet another application, thepneumatic switch 5620 is used to shut down the welding process once theweld has reached a predetermined displacement or it could be used toslow the welding process by altering any number of weld parameters suchas rotational speed or axial pressure as the pneumatic switch isactivated.

FIG. 57 is side-view diagram of an ultrasonic enhanced friction welder5700, according to an implementation. An ultrasonic exciter 5702, anultrasonic power source and controller 5704 are added to the portablefriction forge bonder (PFFB) 3300. The ultrasonic exciter 5702 isoperably coupled to drive shaft 3410. By adding ultrasonic energy to thewelding process, an enhanced weld can be achieved. The ultrasonic energyis transferred from the ultrasonic exciter 5702 down drive shaft 3410,through the pneumatic motor 3302, actuator 3304 and chuck 3306, downthrough the boss or PUR 4302 and into the work piece. This ultrasonicenergy provides a stirring of the weld as it forms, creating a weld witha more homogenous metallurgical structure. In addition, the energyimparted by the ultrasonic exciter is additive with the rotationalenergy produced by the motor and transferred through the actuator 3304.This reduces the energy output requirement of the pneumatic motor 3302and actuator 3304. An ultrasonic exciter 5702 is only one of manydevices that can be attached to the friction welder to add mechanicalvibrational energy to the welding process. Any type of vibrationalenergy could be used in place of the ultrasonic energy for improving theweld joint. The drive shaft 3410 could be solid or comprised of morethan one piece connected together. If the drive shaft 3410 is more thanone piece connected together, the connections would have to be capableof transferring the vibrational energy to the boss 3902. The ultrasonicexciter 5702 can also be placed between pneumatic motor 3302 andactuator 3304.

FIG. 58 is an isometric view of an injection port skirt for receiving anisolation gate to seal the valve 5800, according to an implementation. Askirt 5802 is added to a valve bonnet during or after valve 5800manufacturing. The skirt 5802 for receiving an isolation gate 410.Isolation gate 410 installed as part of an injection system 302 forsealing the valve 5800. A single skirt hole 5804, multiple skirt holesor no skirt holes can be located around the skirt 5802. The skirt 5802may or may not include threaded or non-threaded holes 5804 at a depthequal to the valve bonnet wall. Skirt hole 5804 threads match thethreads on isolation gate 410. Hole 5804 threads sized to receiveisolation gate 410. If valve 5800 needs to be sealed, a hole 5804 orholes are drilled into the skirt 5802 and then tapped if threaded holesdo not already exist. Isolation gate 410 is then screwed into thethreads along with the remainder of injection system 302. A hole isdrilled through the valve bonnet wall using injection system 302 tocontain chemical as described previously. Sealant is injected and anisolation gate 410 is closed all without releasing chemicals into theenvironment. The injection system 302 is removed while leaving theisolation gate 410 behind to contain leakage from the hole 5804. Theskirt 5802 eliminates the need to friction weld a boss or PUR 4302 tothe valve 5800, reducing the complexity, cost and hazards of sealing thevalve 5800.

FIG. 59 is an isometric view of a sealant cage 5900 for providing morespace for injected sealant during a valve leak repair, according to animplementation. FIG. 60 is side view block diagram of a valve 6000 thatcontains a sealant cage 5902, according to an implementation.Frequently, when a valve leak is repaired, there is little room for thesealant 4610 to penetrate the circumference of gland packing 216. Byinstalling the sealant cage 5902 in FIG. 59 into gland packing 216 asshown in FIG. 60 , a space is reserved for sealant 4610 to be filledduring a valve repair. The sealant cage 5902 can be added duringmanufacturing of the valve or during re-assembly of the valve after ithas been taken apart for rebuilding. The sealant cage 5902 is made oftwo plates 5904 and 5906 and multiple supports 5910 that hold the twoplates 5904 and 5906 apart. The plates 5904 and 5906 are doughnut shapedand may have hinges or fasteners 5908 to allow them to be split into twoparts to make assembly around the valve stem 5912 easier. The sealantcage 5902 prevents material such as gland packing 216 from entering thespace between the two plates 5904 and 5906. When repairing a leakingvalve that contains a sealant cage 5902, a boss or PUR 4302 is installedjust outside the valve wall from the space created by the sealant cage5902. This alignment allows the injected sealant 4610 to easily enterthe space within the sealant cage 5902 when the sealant 4610 isinjected. The sealant cage 5902 can be made of any material or anynumber of materials such as metal, plastic, fiberglass, carbon fiber orany sturdy material.

FIG. 61 is a cross section view of one-half of a pipe or valve flange6100, according to an implementation with injection ports. The flange6100 has an injection port 6102, a channel 6104 for sealant 4610 and/ora gasket (not shown), a boss or PUR 4302, assembly bolt holes 6108 andexhaust or injection port 6106. To complete the flange 6100, thesecond-half of the flange (not shown) is operably coupled to the firsthalf with bolts assembled through the assembly bolt holes 6108. Thesecond-half of the flange (not labeled) is similar to the first-half ofthe flange 6100, but without the injection port 6102 and 6106 or bosses4302. When the two halves of the flange 6100 are assembled, a gasket canbe placed in the channel for sealant or it can be left empty. After thebolts are tightened, an injection system 302 is attached to the boss orPUR 4302 aligned with injection port 6102 and isolation gate 410 isattached to the other boss or PUR 4302. After injection system 302 isattached, sealant 4610 is injected into the channel 6104 for sealant4610 in and around the gasket if one was installed. The boss or PUR4302, with an isolation gate 410 attached, will act as a bleeder toallow chemical that has leaked into the channel 6104 for sealant 4610 toescape to avoid vapor lock. Isolation gate 401 is used to open or closechemical flow through the bleeder. Without this bleeder in some leakingflanges, there would be no room for the sealant 4610 in the channel6104. A chemical trap or filter 4608 can be attached to isolation gate401 as shown in FIG. 46 to displace chemicals from the channel 6104 forsealant 4610 during the injection process. The channel 6104 for sealant4610 can be re-injected many times after the flange 6100 is installedbefore or during operation to repair leaks if necessary. Isolation gates410 or set screws can be operably coupled to the bosses or PURs 4302 tokeep them sealed after the injection process is complete. The bosses orPURs 4302 can be attached in the factory or in the field before or afterassembly of the two flange halves.

FIG. 62A is a cross section view of an injectable flange gasket 6200,according to an implementation. FIG. 62B is an isometric view of aninjectable flange gasket 6200, according to an implementation. Aninjectable flange gasket 6202 is used as a proactive solution to repairpipe flange leaks and is used in place of other flange gaskets and hasan outer diameter that is approximately equal to the outer diameter ofthe two flange halves 6204. Injectable flange gasket 6202 is comprisedof two gaskets, typically spiral wound gaskets 6206, a groove or channel6208, a flange pipe 6210, bolt holes 6212, a boss or PUR 4302 that isoperably coupled to the injectable flange gasket 6202 and a hole 6214between the boss or PUR 4302 and the groove or channel 6208. The hole6214 is aligned so that sealant 4610 can flow between the boss or boss4302 and the groove or channel 6208. Once the injectable flange gasket6202 is installed and bolted between the two flange halves 6204,injection system 302 can be operably coupled to the boss or PUR 4302.Injection system 302 can be used to inject sealant 4610 into the grooveor channel 6208 upon assembly of the injectable flange gasket 6200 orafter the injectable flange gasket 6200 begins to leak. The body ofinjectable flange gasket 6202 can be made from metal, a compound, apolymer or any material that would provide a good base for a gasket andthat is capable of accepting a mounted boss or 4302.

FIG. 63 is an isometric view of a threaded cup containment device 6300for adding a backup seal for the isolation gate 410, according to animplementation. After a valve is repaired and an isolation gate 410 isleft in place, in time the gate or the threads between the isolationgate 410 and the boss 312 may start to leak. To contain this leak, a cupwith thread 6302 can be mounted over the isolation gate 410 to provide asecond layer or backup seal for the isolation gate 410. Before theisolation gate 410 is operably coupled to the boss 312, a cap 6304 isinstalled and held in place by the isolation gate 410. The threaded cup6302 is installed over the isolation gate 410 and screwed into the cap6304 with interior threads. This cup 6302 and cap 6304 assemblycombination is used to collect any chemical leakage from the isolationgate 410. If the interface between the boss 312, cap 6304 and isolationgate 410 does not create a good seal, then washers with center holesabout the diameter of the isolation gate 410 threads can be installed oneach side of the cap 6304. The cup 6302 and cap 6304 can be made out ofmetal, carbon fiber, polymers, compounds or any material that is capableof providing a good seal with durability.

FIG. 64A is an isometric diagram of a multi-motor drive system fordoubling the drive capability of a portable friction welding system6400, according to an implementation. FIG. 64B is a bottom view blockdiagram of a multi-motor drive system for doubling the drive capabilityof a portable friction welding system 6400, according to animplementation. Motor A 6402 and motor B 6404 are mounted on a platform6406. In some implementations, motors 6402 and 6404 are pneumaticmotors. Gear A 6408 is connected to the end of the drive shaft of motorA 6402 on the bottom side of the platform 6406 and gear B is connectedto the end of the drive shaft of motor B 6404 on the bottom side of theplatform 6406. Gear C 6410 is meshed with gear A 6408 and gear B 6412 onthe bottom side of the platform 6406 and connected to the drive shaft ofthe actuator 6414. The chuck 3306 is connected axially to the actuator6414 and the boss 312 is mounted in the chuck 3306. Hose A 6416 and hoseB 6418 connect a controller and a compressed air source 6420 to motor A6402 and motor B 6404. When the controller and compressed air source6420 activate motor A 6402 and motor B 6404, gear A 6408 and gear B 6412drive gear C 6410 in the opposite rotational direction which in turndrives the actuator 3304 in that same opposite rotational direction. Ifgear A 6408, gear B 6412 and gear C 6410 are the same size, then thetorque and horsepower transferred to the actuator will be double that ofa single motor, which will allow a larger diameter stud or boss 312 tobe friction welded to a work piece with a portable friction welder.Three or more motors could be added to the portable friction weldingsystem 6400 to further to multiply the torque and horsepower transferredto the actuator 3304. Different gear ratios could be used multiply ordivide the torque transferred from the motors 6402 and 6404 to theactuator 3304. For example, if gear A 6408 and gear B 6412 contain halfthe number of teeth as gear C 6410, torque transferred to the actuator3304 would increase by a factor of two and the rotational speed would bereduce by a factor of two. Likewise, if gear A 6408 and gear B 6412 havemore teeth than gear C 6410, torque would be decreased and rotationalspeed would be increased. It is necessary for the compressed air source6420 to be capable of delivering twice the air volume at the samepressure as is necessary for driving a portable friction forge bonder(PFFB) 3300. A chain and sprocket or belt and sprocket drive mechanismcan add together and transfer the energy from the motors 6402 and 6404to the actuator 3304. A transmission, differential or any mechanicalcoupler could also be used in place of the gears 6408, 6410 and 6412shown in FIG. 64B. Two separate controller and compressed air sources6420 could be used, one controller with two compressed air sources ortwo controllers with one compressed air source. It should be obvious toone skilled in the art that other power sources and controllers could beused in place of the controller and compressed air source 6420 anddifferent controllers could be used for controlling these differingpower sources. If different controllers and power sources are use,different motors would also have to be used. For example if electriccontrollers and power sources are used, then electric motors must alsobe used.

FIG. 65 is a block diagram of a multi-motor drive system for doublingthe drive capability of a portable friction welding system, according toan implementation. Pneumatic motor 3302 and pneumatic motor 3303 aremounted together, axially aligned in a series configuration. The driveshaft of motor 3302 and motor 3303 are operably and axially coupledtogether. Motor 3302 is axially and operably coupled to one end of theactuator 3304 and the boss 3306 is operably and axially connected to theother end of the actuator 3304. A boss or boss 3310 is mounted in thechuck 3306 in preparation for a weld. Hose 3316 connects controller andhigh volume air compressor 3312 to motor 3302 and hose 3317 connectscontroller and high volume air compressor 3313 to motor 3303. Controllerand high volume air compressor 3312 controls the flow of air to motor3302 and controller and high volume air compressor 3313 controls theflow of air to motor 3303. The controller portion of controller and highvolume air compressor 3312 and 3313 control the volume and pressure ofair in an on and off manner. A more sophisticated controller could beused to vary the volume and/or pressure of air during the frictionwelding process. When controller and high volume air compressor 3312 and3313 activate motor 3302 and motor 3303, the coupled drive shaftstransfer the torque from motor 3302 and motor 3303 in the samerotational direction to drive the actuator 3304. Unlike the multi-motordrive system of FIG. 64 , different gear ratios cannot be used withoutthe addition of a gear box between motor 3302 and actuator 3304.Therefore, the torque and horsepower transferred to the actuator 3304will be double that of a single motor, which will allow a largerdiameter stud or boss 3310 to be friction welded to a work piece with aportable friction welder. Three or more motors could be added to thismulti-motor drive system 6500 in series to further multiply the torqueand horsepower transferred to the actuator 3304. It is necessary for thecontroller and high volume air compressor to be capable of deliveringtwice the air volume at the same pressure as is necessary for driving atwo motor system. One controller and high volume air compressor could beused, one controller with two high volume air compressors or twocontrollers with one high volume air compressor. Other power sources andcontrollers could be used in place of the controller and high volume aircompressor and different controllers could be used for controlling thesediffering power sources. If different power sources are use, differentmotors would also have to be used. For example if electric controllersand power sources are used, then electric motors must also be used.

In this disclosure, friction welding, friction bonding, solid-statewelding, friction forging, friction forge bonding, friction forgewelding, inertia welding and inertia bonding are all used synonymously.Boss and permanent universal receiver (PUR) are also used synonymously.MIG welding, TIG welding, GMAW, GTAW, FCAW, SMAW and arc welding areused synonymously in this disclosure.

A technical effect of the apparatus and methods of FIG. 3-65 is thatpositive pressure is provided into a pipe or valve, and the positivepressure significantly reduces or eliminates release of hazardousmaterial from inside the valve or pipe and thus significantly reducesemission of the hazardous material from inside the pipe or valve intothe environment endangering the technician and the environment. Theinjection system of FIGS. 3-6 and 9-10 is also known as a containmentsystem because the positive pressure of the injection system containsthe hazardous material within the valve or pipe.

The Abstract of the Disclosure is provided to comply with 37 C.F.R. §1.72(b) and is submitted with the understanding that it will not be usedto interpret or limit the scope or meaning of the claims. In addition,in the foregoing Detailed Description of the Drawings, various featuresmay be grouped together or described in a single embodiment for thepurpose of streamlining the disclosure. This disclosure is not to beinterpreted as reflecting an intention that the claimed embodimentsrequire more features than are expressly recited in each claim. Rather,as the following claims reflect, inventive subject matter may bedirected to less than all of the features of any of the disclosedembodiments. Thus, the following claims are incorporated into theDetailed Description of the Drawings, with each claim standing on itsown as defining separately claimed subject matter.

The above disclosed subject matter is to be considered illustrative, andnot restrictive, and the appended claims are intended to cover all suchmodifications, enhancements, and other embodiments which fall within thetrue spirit and scope of the present disclosed subject matter. Thus, tothe maximum extent allowed by law, the scope of the present disclosedsubject matter is to be determined by the broadest permissibleinterpretation of the following claims and their equivalents, and shallnot be restricted or limited by the foregoing detailed description.

The invention claimed is:
 1. An apparatus comprising: a curved structurehaving an exterior surface, having an interior surface and having adefect; a gasket positioned over the defect in the curved structure, thegasket having a length, a width and a thickness; a rigid patchpositioned over the gasket, the rigid patch having a length, a width anda thickness, the length of the rigid patch being greater than the lengthof the gasket, the width of the rigid patch being greater than the widthof the gasket; a block patch in between the rigid patch and the exteriorsurface of the curved structure; and a plurality of studs and nutspositioned near an outer perimeter of the rigid patch, the plurality ofthe studs being friction welded to the exterior surface of the curvedstructure.
 2. The apparatus of claim 1 wherein the gasket furthercomprises: a rubber gasket.
 3. The apparatus of claim 1 wherein thegasket further comprises: an epoxy resin or polymer.
 4. The apparatus ofclaim 1 wherein the gasket further comprises: a perimeter gasket.
 5. Theapparatus of claim 1 wherein the rigid patch further comprises: a metalpatch.
 6. The apparatus of claim 1 wherein the rigid patch furthercomprises: a soft metal patch.
 7. The apparatus of claim 1 wherein therigid patch further comprises: a polymer patch.
 8. The apparatus ofclaim 1 wherein the rigid patch has an equal number of mounting holes asstuds and each of the studs passes through a corresponding mounting holeand at least one of the mounting holes further comprise: an elongatedmounting hole.
 9. The apparatus of claim 1 wherein a geometric shape ofthe rigid patch further comprises: a square geometric shape.
 10. Theapparatus of claim 1 wherein a geometric shape of the rigid patchfurther comprises: a round geometric shape.
 11. The apparatus of claim 1wherein a geometric shape of the rigid patch further comprises: arectangular geometric shape.
 12. The apparatus of claim 1 wherein eachof the nuts further comprise: a standard nut.
 13. The apparatus of claim1 wherein each of the nuts further comprise: a locking nut.
 14. Theapparatus of claim 1 wherein each of the nuts further comprise: a tamperresistant nut.
 15. An apparatus comprising: a curved structure having anexterior surface, having an interior surface and having a defect; asteel patch positioned over the exterior surface of the curvedstructure; a block patch in between the steel patch and the exteriorsurface of the curved structure; and a plurality of studs and nutspositioned near an outer perimeter of the steel patch, the plurality ofthe studs being friction welded to the exterior surface of the curvedstructure.
 16. The apparatus of claim 15 further comprising: a gasketpositioned over the defect in the curved structure and under the blockpatch.
 17. The apparatus of claim 16 wherein the gasket furthercomprises: a rubber gasket.
 18. The apparatus of claim 16 furthercomprising: the steel patch having a length, a width and a thickness,the length of the steel patch being greater than the length of thegasket, the width of the steel patch being greater than the width of thegasket.
 19. The apparatus of claim 16 wherein the gasket furthercomprises: an o-ring.
 20. An apparatus comprising: a curved structurehaving an exterior surface, having an interior surface and having adefect; a gasket positioned around the defect in the curved structure,the gasket having a length, a width and a thickness; a rigid coverpositioned over the gasket, the rigid cover having a length and a widthand a thickness; a block patch in between the rigid cover and theexterior surface of the curved structure; and a plurality of studs andnuts positioned near an outer perimeter of the rigid cover, theplurality of the studs being friction welded to the exterior surface ofthe curved structure.